Zero one

Four major culprits of poor quality

The four major culprits of poor quality come from the four links of the product production process, namely:

The wrong and poor design leads to the inherent deficiency of the product.

Too complex design, resulting in high cost, low quality.

Frequent design changes make the process confusing and prone to errors.

2

Lack of process flow, BOM.

Operating standards are lacking, wrong or inappropriate.

There is no correct and reliable fixture.

Lack of complete and correct inspection standards.

Failure to properly understand and enforce operating standards.

Insufficient process control capacity.

Improper process quality audit and inspection.

Lack of quality awareness and quality responsibility.

4

The incoming material is of poor quality.

The production plan is too rough, changeable, loose and tight.

Mismanagement and weak leadership.

Poor storage management.

02

From the perspective of process analysis, the reasons for poor quality can be summarized from four aspects:

1

The reason:

New employees: New employees are not familiar with the work process and lack the necessary operational skills and knowledge.

Inadequate competence: An employee lacks the professional skills or attitude needed to do the job.

Poor instruction: Inadequate training or guidance or improper methods, resulting in employees not mastering the correct methods of work.

Countermeasures:

Develop operating standards: Ensure that all employees have clear operating instructions and workflow.

Apportionment: Allocate work appropriately according to the ability and skills of employees.

Do a good job teaching employees: Implement a systematic training plan to ensure that employees fully understand the job requirements and processes.

2

The reason:

Lack of tools: Employees do not have the proper tools or equipment to do their jobs.

Using the wrong tools: Employees use the wrong tools or equipment, resulting in work errors.

Misunderstanding of standards: An inaccurate or inadequate understanding of working standards.

Lack of foolproof design: Workflows or equipment lack a design to prevent errors from occurring.

Negligence: Errors resulting from inattention or carelessness.

Countermeasures:

Process institutionalization: Ensure workflow standardization and reduce uncertainty.

Work standardization: Develop and implement uniform work standards.

Job simplification: Simplify workflow and reduce complexity.

Tool stupidity: Use intelligent tools or devices to reduce human error.

3

The reason:

Poor feeding: The use of substandard raw materials or components.

Pre-process problems: Problems in the previous process affect the current process.

Equipment accuracy issues: Equipment does not achieve the required accuracy.

Incorrect instructions: Employees receive incorrect instructions or instructions.

Faulty standards: The working standards themselves are faulty or inadequate.

Inappropriate Method: The method used is not appropriate for the current job or environment.

Countermeasures:

Prevention of undesirable entry: inspection and control of raw materials and components.

Equipment maintenance and early warning: regular maintenance of equipment, establish early warning system to prevent equipment problems.

Three principles: do not accept, do not manufacture, do not deliver defective products, strengthen quality awareness.

Correct principles for field problems: Ensure that employees understand the correct methods and principles for handling field problems.

4

The reason:

Management problems: management pays insufficient attention to quality management or improper management methods.

Organizational problems: The organization structure or process is unreasonable, affecting the work motivation and efficiency of employees.

Lack of stress: Employees do not have enough pressure or motivation to work.

Lack of motivation: Employees lack incentives to improve quality.

Countermeasures:

Quality evaluation: Stimulate employees' quality awareness through competition.

Implement QCC: Encourage employees to participate in quality control circle activities to enhance their sense of participation and responsibility.

Training of grass-roots cadres: training of grass-roots managers to improve their management ability and quality awareness.

Review and revise the system regularly: ensure that the company system is incentivized and can stimulate the enthusiasm of employees.

Establish appropriate attribution of responsibility: Clarify the duties and responsibilities of employees to ensure the effectiveness of quality management.